1D
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Reference: Main Bearings, Crankshaft and Cylinder Block Components:K9K
Removal
1) Remove engine assembly from vehicle referring to Engine Assembly Removal and Installation:K9K .
2) Remove oil pan and oil pump strainer referring to Oil Pan and Oil Pump Strainer Removal and Installation:K9K .
3) Remove exhaust manifold referring to Exhaust Manifold Removal and Installation:K9K .
4) Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation:K9K .
5) Remove timing belt, belt tensioner, crankshaft pulley and timing belt cover referring to Timing Belt and Belt Tensioner Removal and Installation:K9K .
6) Remove heat exchanger referring to Heat Exchanger Removal and Installation:K9K .
7) Remove oil pump, oil pump drive sprocket and gasket holder plate referring to Oil Pump and Oil Pump Chain Removal and Installation:K9K .
8) Remove power steering pump referring to P/S Pump Removal and Installation .
9) Remove camshaft referring to Camshaft and Tappet Removal and Installation:K9K .
10) Remove cylinder head assembly referring to Valves and Cylinder Head Assembly Removal and Installation:K9K .
11) Remove piston and connection rod referring to Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation:K9K .
12) Remove clutch cover, clutch disc and flywheel referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation:K9K Model .
13) Loosen crankshaft bearing cap bolts in such order as indicated in the figure a little at a time, and remove bearing caps.
14) Remove crankshaft from cylinder block.
15) Remove flywheel side crankshaft oil seal from crankshaft.
16) Remove main bearings (1) and thrust bearings (2).
17) Remove oil jet as follows, if necessary.
a) Pack rag into cylinder to prevent swarf from entering.
b) Remove spring stop (1) and spring (2) using 7 mm (0.28 in.) diameter drill (4).
CAUTION:
Do not remove ball (3) to prevent swarf from entering cooling circuit.
c) Desorb swarf from cylinder and oil jet.
d) Install special tool (A) to drilled hole of oil jet (1).
e) Remove oil jet from cylinder using special tools (A and B).
Special Tool
(A) : 09916–48120
(B) : 09916–58120
Installation
Reference: Main Bearings, Crankshaft and Cylinder Block Inspection:K9K
NOTE:
• Whenever crankshaft and cylinder block replaced, select applicable piston referring to Pistons, Piston Rings, Connecting Rods and Cylinders Inspection:K9K .
• All parts to be installed must be perfectly clean.
• Be sure to apply oil to crankshaft journals, main bearings and thrust bearings.
• Main bearings, main bearing caps, connecting rods, connecting rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.
1) Using special tool, install oil jet to cylinder block as follows, if removed.
Special Tool
(A) : 09916–58110
1. Oil jet No.1 4. Oil jet No.4 7. Plate
2. Oil jet No.2 5. Flywheel side 8. Guide rod
3. Oil jet No.3 6. Push rod 9. Plate bolt
a) Install plate (1) to cylinder block tightening plate bolts (2) by hand.
b) Install guide rod (3) to plate aligning guide rod end with oil jet hole.
[A]: Oil jet No.2 and 4 [B]: Oil jet No.1 and 3
c) Tighten plate bolts, and remove guide rod.
d) Insert oil jet (1) into push rod (2) facing oil jet with center of cylinder.
e) Using hammer, tap push rod until push rod (1) comes into contact with plate (2).
[A]: Oil jet No.2 and 4 [B]: Oil jet No.1 and 3
f) Remove special tool.
2) Using special tool, install main bearing to cylinder block and bearing cap as follows.
NOTE:
One of two halves of main bearing has oil groove. Install main bearing with oil grove to cylinder block, and the other one without oil groove to bearing cap.
Special Tool
(A) : 09913–78110
a) Install special tool (A) to cylinder block.
b) Fit main bearing (1) in special tool (A) as shown, and then press at “a” until main bearing is touched at “b”.
c) Install special tool (A) to bearing cap (1).
d) Fit main bearing (1) in special tool (A) as shown, and then press at “a” until main bearing is touched at “b”.
3) Install thrust bearings (1) to center of crankshaft journal facing its oil groove (2) to outside.
4) Install crankshaft to cylinder block.
5) Apply sealant to cylinder block as shown in the figure.
“A” : Sealant ( Loctite rhodorseal 5661® )
“a”: 4 mm (0.16 in.)
6) Install main bearing caps in proper position matching cylinder number marked in removal.
7) Tighten main bearing cap bolts as follows.
a) Tighten bolts to 25 N·m (2.5 kgf-m, 18.0 lbf-ft).
b) Retighten them by turning through 47°.
Tightening torque
Main bearing cap bolt ( a ): Tighten 25 N·m (2.5 kgf-m, 18.0 lbf-ft) and 47° by the specified procedure
NOTE:
After tightening cap bolts, check to be sure that crankshaft rotates smoothly.
8) Using special tool, install flywheel side oil seal as follows.
CAUTION:
Do not touch oil seal so that it is extremely fragile. Whenever installing new oil seal, it must be installed using special tool (A) and protector supplied with new oil seal. If it doesn't follow the above-mentioned service, it may cause oil leak from oil seal.
Special Tool
(A) : 09911–98110
1. Fitting 2. Installer 3. Nut 4. Screw
a) Install fitting (1) and screw (2) to crankshaft.
b) Install protector (4) together with new oil seal (1) to fitting by tightening nut (2) until installer (3) comes into contact with cylinder block.
c) Remove special tool and protector.
9) Install piston and connecting rod referring to Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation:K9K .
10) Install oil pump, oil pump drive sprocket and gasket holder plate referring to Oil Pump and Oil Pump Chain Removal and Installation:K9K .
11) Install oil pan and oil pump strainer referring to Oil Pan and Oil Pump Strainer Removal and Installation:K9K .
12) Install cylinder head assembly referring to Valves and Cylinder Head Assembly Removal and Installation:K9K .
13) Install camshaft referring to Camshaft and Tappet Removal and Installation:K9K .
14) Install timing belt, belt tensioner, crankshaft timing sprocket and timing belt cover referring to Timing Belt and Belt Tensioner Removal and Installation:K9K .
15) Install cylinder head cover referring to Cylinder Head Cover Removal and Installation:K9K .
16) Install flywheel referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation:K9K Model .
17) Install exhaust manifold referring to Exhaust Manifold Removal and Installation:K9K .
18) Install turbocharger referring to Turbocharger Removal and Installation:K9K .
19) Install clutch to flywheel referring to Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation:K9K Model .
20) Install engine mounting brackets.
Tightening torque
Engine right mounting nut ( a ): 55 N·m ( 5.5 kg-m, 40.0 lb-ft)
Engine left mounting nut ( b ): 40 N·m ( 4.0 kg-m, 29.0 lb-ft)
Engine side mounting bracket bolt ( c ): 40 N·m ( 4.0 kg-m, 29.0 lb-ft)
21) Install engine assembly to vehicle referring to Engine Assembly Removal and Installation:K9K .